Pile fabric



Plil 17, 1934- H. L. sHuTTLEwoRTH 1,955,023

PILE FABRIC Filed Oct. '7, 1932.,

ATTORNEY Patented Apr. 17, 1934 UNITED STATES PATENT? oFFicE PILE FABRIC Application October '7, 1932, Serial No. 636,641

7 Claims.

This invention relates to woven pile fabrics, such as are used for rugs and carpets. More particularly, the invention is concerned with a double faced reversible fabric involving novel features of construction, by virtue of which the fabric has great softness and the necessary body, and the pile tufts which are disposed on opposite faces of the fabric are secured firmly in position.

In the manufacture of double faced fabrics for floor coverings, a number of methods of weaving have heretofore been employed. One method involves the use of the so-called Smyrna construction in which a round chenille fur is rst produced, and then used as a weft with ordinary warp threads in the weaving of a fabric. Since the fur is soft and the warp threads employed in this construction are light, a fabric produced in this manner does not have the required body stiffness. In addition, it is costly to manufacture because of the separate weaving operation required for the production of the fur, and ne sharp designs are not obtainable.

Attempts have been made to produce a double faced floor fabric by first weaving a double pile fabric on a face to face loom, severing the tuft yarns to produce two single fabrics, and then removing certain portions of the binding from the single fabrics to allow a'portion of the tufts to be pulled through from the face to the back, so that the tufts are exposed on both faces of the ground web or body of the fabric. This method is not satisfactory, however, since the weaving operations are slow and expensive, a waste of material results, and the fabric does not have the necessary stiffness in the body or web.

The present invention is accordingly directed to the provision of a double fa'ced reversible fabric of novel construction which overcomes the disadvantages of the fabrics produced in accordance with the methods above described, and the new fabric produced in accordance with the principles of the invention has a pile surace'on each face of the ground web, which may have clear cut designs. At the same time, the body has the required stiffness, and the fabric can be Woven in a single weaving operation at high speed with resultant low cost.

The new fabric may be woven on an ordinary Axminster loom with the combing mechanism removed and it preferably includes three shots of weft per row of tufts, binder warps, and one or more stuffer warps. In the preferred construction, the fabric is of the three-plane type with one shot of weft of each cycle lying above the upper stuffer warps, another shot between the stuifer warps, and the third below the lower stuifer warps. The binder warps used pass over the top weft shots and below the bottom weft shots, and each pile tuft is formed of a single end of yarn which projects out of the fabric on its opposite faces and is held in place in the body of the fabric by being interlaced with the weft shots in the manner presently to be described.

For a better understanding of the invention, reference may be had to the accompanying drawing, in which Fig. 1 is a sectional view of one form of the new fabric with the threads spread part so that the construction may be more readily understood.

Figs. 2, 3, 4, 5 and 6 are similar views showing modified forms of the construction.

In the drawing, the fabric illustrated in Fig. 1 is one form of embodiment o-f the principles of the invention, this fabric being of the three-plane type comprising stuffer warp threads 10 and 11 in upper and lower levels, respectively, and Weft shots 1 2, 13, and 14 arranged in cycles of three. The bottom weft shot 12 of each cycle lies below the lower stuifer warps l1, the middle shot 13 lies between the upper and lower stuffer warps 10 and 11, and the top weft shot 14 lies above the upper stuffer warps 10. In inserting the weft shots in the fabric, the shot 13 is first introduced, followed by shots 12 and 14 in that order.

In this form of the fabric, the pile tufts 15 are formed of single ends of yarn whichvare introduced into the fabric in such manner that all shots of a cycle lie at one side of the yarn and the latter is bound between shots of adjacent cycles. As the shots are beaten up, each yarn has a portion engaged from above by the top weft shot of one cycleY and another portion engaged from beneath by the middle weft shot of the succeeding cycle. As the yarn does not pass straight through the fabric, it is firmly bound in place by the weft shots of adjacent cycles as illustrated.

In the weave above described, the tuft yarns are inserted after the insertion of a third shot of a cycle and the three shots of each cycle thus lie all at one side of the yarns. If desired, however, theshots may be inserted in another cycle in which the shot 14 is rst inserted, followed by the insertion of the yarns. After this, shots 12 and 13 are inserted. This weave resembles Figure 1 as to the relative positions of the weft shots and yarns but the yarns engage the top weft shot of a cycle at the right side and the middle and bottom shots of the same cycle at the left side.

The fabric includes binder warps 16 inserted in 110 such manner that each binder warp thread passes over the top of top weft shots and beneath bottom weft shots. Specifically, in the fabric shown in Figure 1 and considering the shots of a cycle to lie all at the same side of the tuft yarns, each binder warp thread passes beneath the bottom shot` of each cycle, up at one side thereof and at the same side of the middle shot, thence at the other side of the top shot, over the top shot, and down to the bottom shot of the next succeeding cycle. With this arrangement, the middle shot lies in a loop of the binder warp threads which opens through a face of the fabric and in the fabric illustrated in Figure l, the loop opens through the top face. Considering the fabric to be woven with the top shot at one side of the tuft yarns and the middle and bottom shots at the other side, the binder warp threads pass over the top of the top shot of a cycle, down at one side of the middle and4 bottom shots of that cycle, beneath the bottom shot and then up at the *other side of the bottom and middle shots ofthe cycle tothe top shot of the next succeeding cycle .o

Yvl`In the construction illustrated in Fig. 2, the same elements are employed, but, in this construction, each pile yarn engages the top and bottom shots Yof a cycle from one side and is looped around the middle weft shot of the cycle andengages it from the opposite side. A single set of binder warps 16 is employed and these warp threads pass under the bottom shot of each cycle, overA the top -of that shot, upjat `one side ofthe middle shot, over and around the top shot, down 'ai-,the lsame side of the middle shot, and thence over the top of therbottom shotand to the bottom shot ofthe next cycle. With this arrangement, each middle shot of the cycle lies in a loop of the binder warp threads opening in the plane of the fabric. This arrangement results in the pile yarns being effectively bound in place as the upper weft shot of each cycle engages a portion of the 'pile yarn from above, while this same portion of the yarnv is engagedfrom beneath by the middle shot of the cycle. Similarly, the bottom shot of that cycle engages a portion of the pile yarn from 'beneath while the same portion is engaged from above by the middle weft shot. t y

In the Aconstruction illustrated in Fig. 3, the pile yarnsare inserted in the same manner as in the fabric shown in Fig. 2, but a d iiferent `ar rangement of the binder warps is employed. In the Fig. Sweave, the binder warp threads 16 pass beneath the bottom shot of each cycle, over the tcp of that shot, u p at the same side of the middle and vtop shots, over the top shot, and down at the other side of the top and middle shots to the bottom shot of the next cycle. Thus the middle 'shot lies in a loop of the binder threads, opening through Aa face of the fabric, which, inthe fabric illustrated in Figure 3, is the bottom face. y

In the construction illustrated in Fig. 4, the tuft yarns are bound in the same manner as that usedin the fabricshown in Figs. 2 and 3, but two sets of binder warps 17 and 18 are employed. The warps of the two sets are interwoven in the fabric in such manner that each warp thread passes'over 'the top of the top shot of one cycle, beneath the bottom shot of the next adjacent cycle, and over` the top of the top shot of the third cycle, this arrangement continuing throughout the fabric. In the weavingy of the new fabric in the usual Axminster loom, the binder and stuffer warps are carried on beams vprovided with the customary letff mechanisms for controlling the tension in the warp threads, and the shots of weit are inserted by a needle which travels in and out of the shed formed by the binder warps and the stuffer warps. When the fabric illustrated in Fig. 4 is to be used, an additional heddle and cams must be employed by reason of there being two sets of binder warps. The stuiier war'ps used in that fabric are wound on a single beam and the two` sets of binder warps are also wound on a single beam, both beams being controlled by the 'usual let-off mechanism,

While I have illustrated the two ways of inserting the pile tufts shown in Figs. l and 2, respectively, Aand four different methods of inserting Abinder warp threads, it is to be understood that any arrangement of the pile yarns may be employed with any arrangement of the binder threads as desired.

The new fabric is greatly superior to the prior reversible fabrics with which I am familiar since both faces of -it may be used 'with equal convenience, fine sharp designs may be obtained on both faces, 'the fabric has the required body stiffness for floor coverings, Aand it can be woven in a single operation at a higher weaving speed than an ordinary Axminster fabric. Since the new fabric 'can be made at increased speeds of weaving and at lower cost for materials and labor, it is substantially cheaper than the two prior reversible fabrics which I have described.

What I claim:

l. A reversible pile fabric which comprises stuffer warp threads disposed in upper and lower levels, weft shots lying above, between, and below the stuffer warp threads, pile yarns extending tlf'irough the fabric with their ends projecting vout of the fabric on lopposite sides thereof, each yarn having a 'portion engaged from above by a weft shot lying above vthe upper 'stuffer warp threads 4'and another portion engaged from below by `a weft'sh'ot lying below the lower stuffer warp threads, said yarn being bent around a weft shot lying between the upper and lower stuffer warp threads, and binder warp threads passing yover the tops of the weft shots lying above the upper'stuffer warp threads and underneath the weft shots lying below the lower stuffer warp threads.

2. `A reversible pile fabric lwhich comprises stufier warp threads disposed in upper and lower levels, weft shots inserted in cycles of three,

'andtheoppo'site side of the middle shot of said j; cycle, and binder warp threads passing over the tops of weft shots lying abo-ve the upper stuffer warp threads and underneath the weft shots lying below the lower stuffer warp threads.

3. A reversible pile fabric which comprises stuffer warp threads disposed in upper and lower levels, weft shots inserted in cycles of three, with one shot of each cycle lying above the upper stuifr warp threads, another shot of said cycle lyingV between the upper and lower stuifer warp threads, and the third shot of said cycle lying below the lower stuffer warp threads, pile yarns extending through the fabric with their ends projecting out of the fabric on opposite sides thereof, each yarn being looped around one side of the lic middle weft shot of a cycle and bent back against the opposite side of the top and bottom shots of said cycle, and binder warp threads passing over the tops of weft shots lying above the upper stuffer warp threads and underneath the weft shots lying below the lower stuffer warp threads.

4. A reversible pile fabric which comprises stuffer warp threads disposed in upper and lower levels, weft shots inserted in cycles of three, with one shot of each cycle lying above the upper stuffer warp threads, another shot of said cycle lying between the upper and lower stuffer warp threads, and the third shot of said cycle lying below the lower stuifer warp threads, pile yarns extending through the fabric with their ends projecting out of the fabric on opposite sides thereof, each yarn having portions lying at the same side of the top and bottom shots of each cycle and another portion lying at the opposite side of the middle shot of said cycle, and binder warp threads, each passing over the top of the top shot of each cycle and underneath the bottom shot of said cycle, with the middle shot of said cycle lying in a loop of the binder warp threads opening toward a face of the fabric.

5, A reversible pile fabric which comprises stuffer warp threads disposed in upper and lower levels, weft shots inserted in cycles of three, with one shot of each cycle lying above the upper stuifer warp threads, another shot of said cycle lying between the upper and lower stuifer warp threads, and the third shot of said cycle lying below the lower stuffer warp threads, pile yarns extending through the fabric with their ends projecting out of the fabric on opposite sides Le top shot of each cycle and underneath the bottom shot of said cycle, with the middle shot of said cycle lying in a loop of the binder warp threads opening downwardly.

6. A reversible pile fabric which comprises stuifer warp threads disposed in upper and lower levels, weft shots inserted in cycles of three, with one shot of each cycle lying above the upper stufer warp threads, another shot of said cycle lying between the upper and lower stuffer warp threads, and the third shot of said cycle lying below the lower stuier warp threads, pile yarns extending through the fabric with their ends projecting out of the fabric on opposite sides thereof, each yarn having portions lying at the same side of the top and bottom shots of each cycle and another portion lying at the opposite side of the middle shot of said cycle, and binder warp threads, each passing over the top of the top shot of each cycle and underneath the bottom shot of said cycle, with the middle shot of said cycle lying in a loop of the binder warp threads opening in the plane of the fabric.

7. A reversible pile fabric which comprises stuffer warp threads disposed in upper and lower levels, weft shots inserted in cycles of three, with one shot of each cycle lying above the upper stuifer warp threads, another shot of said cycle lying between the upper and lower stuffer warp threads, and the third shot of said cycle lying below the lower stuffer warp threads, pile yarns extending through the fabric with their ends projecting out of the fabric on opposite sides thereof, each yarn having portions lying at the same side of the top and bottom shots of each cycle and another portion lying at the opposite side of the middle shot of said cycle, and binder warp threads in two sets with the threads of each set passing over the top of the top shot of a cycle and underneath the bottom shot of the next adjacent cycle.

HOWARD L. SHUTTLEWORTI-I. 

